Process for converting a continuous structure into discrete, spaced apart elements

Abstract

The present invention relates to a process for converting a continuous structure into discrete, spaced apart elements by means of an expandable support web. First, the continuous structure is combined with a support web comprising longitudinal expansion means. Then, after separation of the continuous structure into discrete elements, the discrete elements are spaced apart by expanding the support web. The process of the present invention is particularly well suited for the industrial manufacture of articles comprising fragile discrete elements supplied to the production process in continuous form.

What is claimed is:  
     
       1. A process for converting a continuous structure into discrete, spaced apart elements, comprising the steps of: 
       a) supplying a continuous support web which is combined with said continuous structure, said support web comprising at least one longitudinal expansion means;  
       b) separating said continuous structure into said discrete elements by longitudinally expanding said continuous support web at said longitudinal expansion means; and  
       c) longitudinally spacing apart said discrete elements by longitudinally expanding said continuous support web at said longitudinal expansion means.  
     
     
       2. The process according to  claim 1  wherein said support web has at least one deactivatable expansion obstruction means preventing the longitudinal expansion means from being fully expanded prior to the deactivatable expansion obstruction means being deactivated. 
     
     
       3. The process according to  claim 2  further comprising the step of deactivating said deactivatable expansion obstruction means. 
     
     
       4. The process according to  claim 1  wherein said support web is a discontinuously expanding web. 
     
     
       5. The process according to  claim 1  further comprising the step of introducing designated transverse separation zones into the continuous structure. 
     
     
       6. The process according to  claim 1  wherein said expanding of said support web is carried out by a series of two consecutive conveyors transporting said support web, a second of the two conveyors having a higher transportation velocity than a first of the two conveyors. 
     
     
       7. The process according to  claim 1  further comprising the steps of forming said continuous structure and transferring said continuous structure onto said support web. 
     
     
       8. The process according to  claim 1  further comprising the step of forming said continuous structure on said support web. 
     
     
       9. The process according to  claim 1  wherein said discrete elements are absorbent cores. 
     
     
       10. The process according to  claim 1  further comprising the step of separating said continuous support web between at least some said discrete elements to thereby form discrete articles comprising at least one of said discrete elements and at least one piece of said support web. 
     
     
       11. The process according to  claim 10  further comprising the step of folding said support web around at least one longitudinal edge or at least one transverse edge of said discrete elements. 
     
     
       12. The process according to  claim 11  further comprising the steps of longitudinally wrapping said support web around said discrete elements such that the longitudinal edges of said support web overlap and completely enveloping said discrete elements by sealing said support web along the overlapping longitudinal edges of said support web and by sealing said support web outside the transverse edges of said discrete elements. 
     
     
       13. The process according to  claim 10  further comprising the steps of supplying a second support web and positioning said discrete elements intermediate said support web and said second support web. 
     
     
       14. The process according to  claim 13  further comprising the step of completely enveloping said discrete elements by attaching said support web to said second support web outside the longitudinal edges and transverse edges of said discrete elements. 
     
     
       15. The process according to  claim 10  wherein said discrete articles are absorbent articles.